Production of Oxide Ceramic Matrix Composites by a Prepreg Technique

Ceramic matrix composites (CMCs) were developed to overcome the intrinsic brittleness and lack of reliability of monolithic ceramics. Their major advantages include high temperature capability, light weight, corrosion resistance and adequate damage tolerance. All-oxide Ceramic Matrix Composites (OCMCs) offer essential advantages with respect to long time stability in oxidizing atmospheres, when compared to their non-oxide counterparts. Nevertheless, there is at present almost no production concept which meets the requirements in view of cost and performance for these materials. This work aims at producing OCMCs by means of a more flexible production route. This is achieved by integrating well-known powder metallurgy routes with the prepreg technique, used at present for producing commercial high performance polymer matrix composites. The processing consists of the following steps: (a) infiltration of commercial alumina fiber fabrics (3M NextelTM610) with a liquid suspension of the matrix material; (b) lamination of the pre-infiltrated fiber textiles with a paraffin-based suspension for the formation of prepregs; (c) layup of prepregs; (d) warm-pressing for the consolidation of the green body; (e) debinding and (f) reaction bonding and/or sintering for synthesis of the oxide matrix. Pure alumina or Reaction Bonded Aluminum Oxide (RBAO) can be used as matrix materials and damage tolerance is achieved by the porous, weak-matrix approach. Microstructural analysis of a pure alumina composite fabricated by this route show good infiltration of fiber bundles and proves the good adhesion of prepregs during processing. Average strength value of 199 MPa in fiber direction is in good agreement with values presented in the literature for OCMCs produced by other techniques.